Fuel cell bipolar plate alloys

This application is a divisional of U.S. application Ser. No. 18/072,235 filed on Nov. 30, 2022 and issued on Apr. 9, 2024 as U.S. Pat. No. 11,955,669, which is a divisional of U.S. application Ser. No. 16/694,455 filed Nov. 25, 2019 and issued on Dec. 20, 2022 as U.S. Pat. No. 11,532,827, the disclosure of which is incorporated herein by reference in its entirety.

The present disclosure relates to fuel cell bipolar plate alloys where the alloys may form a bulk material and/or a coating material of the bipolar plate.

Fuel cells may be an alternative power source for mobile transportation applications or other applications. Fuel cells may use a renewable energy carrier such as hydrogen. For example, fuel cells may produce electrical power and the byproduct of water from hydrogen (H) and oxygen (O). Fuel cells convert chemical energy into electrical energy. Fuel cells may be stacked to form a fuel cell stack having high voltage and/or power. A common fuel cell is a proton-exchange membrane fuel cell (PEMFC). A PEMFC may include bipolar plates, electrodes, a catalyst or catalyst layer, and a proton-exchange membrane. Bipolar plates can contribute significantly to the weight and cost of a fuel cell. The bipolar plates may provide structural support, conductivity, and may assist in supplying fuel to other components of the fuel cell. Bipolar plates may connect and divide individual fuel cells to form a fuel cell stack. Bipolar plates may also assist in removal of reaction products or byproducts. Bipolar plates may help regulate or manage thermal conditions in a fuel cell. Bipolar plates may be made of metallic compositions or graphite. For example, steel may be utilized because it is relatively inexpensive, stable, conductive and durable. However, many steels, including various grades of stainless steel, struggle to maintain performance in the corrosive environment of a fuel cell and are relatively heavy. This degradation may reduce a fuel cell's life or efficiency. Using graphite for bipolar plates has also been investigated. Graphite generally maintains good corrosive-resistant properties but can be expensive and brittle.

According to at least one embodiment, a bipolar plate of a fuel cell is disclosed. The bipolar plate may include a substrate having first and second surfaces. The first and/or second surface having a surface layer coating. The surface layer coating including an alloy having a formula: CuFeTi, CuNiTi, NiSiTi, CFeSi, AlFeSiAlMnSi, or AlNiSi; where x is present up to 0.885; y is present up to 0.85; z is 0.05 to 0.8; and the sum of x, y, and z is 1.

In one or more embodiments, the alloy has a corrosion current that is less than the corrosion current of the substrate. For example, the corrosion current is less than 10 μA/cm. In one or more embodiments, the bipolar plate of a fuel cell may include an alloy having the formula: CuFeTi; where x is 0.35 to 0.55; y is 0.05 to 0.1; and z is 0.4 to 0.6. In various embodiments, the bipolar plate of the fuel cell may include an alloy having the formula: CuNiTi; where x is 0 to 0.75; y is 0 to 0.45, and z is 0.25 to 0.75. In still other embodiments, the bipolar plate of the fuel cell may include an alloy having the formula: AlFeSi; where x is 0.05 to 0.63; y is 0.12 to 0.85; and z is 0.1 to 0.25. In other embodiments, the bipolar plate of a fuel cell may include an alloy having the formula: AlMnSi; where x is 0.45 to 0.66; y is 0.1 to 0.2; and z is 0.2 to 0.35. In yet another embodiment, the bipolar plate of a fuel cell may include an alloy having the formula: AlNiSi; where x is 0.52 to 0.79; y is 0.04 to 0.23; and z is 0.11 to 0.25. In a variation, the bipolar plate of a fuel cell may include an alloy having the formula: NiSiTi; where x is 0 to 0.64; y is 0 to 0.2; and z is 0.16 to 0.8. In one or more embodiments, the bipolar plate of a fuel cell may include an alloy having the formula: CFeSi; where x is 0.1 to 0.25; y is 0.65 to 0.7; and z is 0.1 to 0.25. In a refinement, the bipolar plate and/or alloy are doped with less than or equal to 1 at. % of an element selected from the group consisting of La, P, B, C, Co, Zr, Cr, Nb, Mo, W, Sn, and a combination thereof. In a variation, the alloy has a partially amorphous structure. In one or more embodiments, the surface coating layer is 1 nm to 500 μm.

In one or more embodiments, bipolar plate of a fuel cell, the bipolar plate including an alloy having a formula: CuFeTi, CuNiTi, NixSiTi, CFeSi, AlMnSi, or AlNiSi; where x is present up 0.885; y is present up 0.85; z is 0.05 to 0.8 and the sum of x, y, and z is 1.

In a refinement, the alloy has a partially amorphous structure. In a variation, the bipolar plate includes an alloy having the formula CuFeTi; where x is 0.35 to 0.55; y is 0.05 to 0.1; and z is 0.4 to 0.6.

In one or more embodiments, a fuel cell including a proton exchange membrane, a plurality of catalyst electrode layers; and bipolar plates including an alloy having a formula:

CuFeTi, CuNiTi, NiSiTi, CFeSi, AlMnSi, or AlNiSi; where x is present up to 0.885; y is present up to 0.85; z is 0.05 to 0.8 and the sum of x, y, and z is 1.

In a variation, the alloy has a partially amorphous structure. In various embodiments, the fuel cell includes the alloy having the formula: CuNiTi; where x is 0 to 0.75; y is 0 to 0.45, and z is 0.25 to 0.75. In other embodiments, the fuel cell includes the alloy having the formula: AlFeSi; where x is 0.05 to 0.63; y is 0.12 to 0.85; and z is 0.1 to 0.25.

Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments can take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the embodiments of the present invention. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.

Except in the examples, or where otherwise expressly indicated, all numerical quantities in this description indicating amounts of material or conditions of reaction and/or use are to be understood as modified by the word about in describing the broadest scope of the invention. Practice within the numerical limits stated is generally preferred. Also, unless expressly stated to the contrary: percent, “parts of,” and ratio values are by weight; the term “polymer” includes “oligomer,” “copolymer,” “terpolymer,” and the like; the description of a group or class of materials as suitable or preferred for given purpose in connection with the invention implies the mixtures of any two or more of the members of the group or class are equally suitable or preferred; molecular weights provided for any polymers refers to number average molecular weight; description of constituents in chemical terms refers to the constituents at the time of addition to any combination specified in the description, and does not necessarily preclude chemical interactions among the constituents of a mixture once mixed; the first definition of an acronym or other abbreviation applies to all subsequent uses herein of the same abbreviation and applies mutatis mutandis to normal grammatical variations of the initially defined abbreviation; and, unless expressly stated to the contrary, measurement of a property is determined by the same technique as previously or later referenced for the same property.

This invention is not limited to the specific embodiments and methods described below, as specific components and/or conditions may vary. Furthermore, the terminology used herein is used only for the purpose of describing particular embodiments of the present invention and is not intended to be limiting in any way.

As used in the specification and the appended claims, the singular form “a,” “an,” and “the” comprise plural referents unless the context clearly indicates otherwise. For example, reference to a component in the singular is intended to comprise a plurality of components.

The term “substantially,” “generally,” or “about” may be used herein to describe disclosed or claimed embodiments. The term “substantially” may modify a value or relative characteristic disclosed or claimed in the present disclosure. In such instances, “substantially” may signify that the value or relative characteristic it modifies is within ±0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5% or 10% of the value or relative characteristic.

With respect to the terms “comprising,” “consisting of,” and “consisting essentially of,” where one of these three terms is used herein, the presently disclosed and claimed subject matter can include the use of either of the other two terms.

It should also be appreciated that integer ranges explicitly include all intervening integers. For example, the integer range 1-10 explicitly includes 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Similarly, the range 1 to 100 includes 1, 2, 3, 4 . . . 97, 98, 99, 100. Similarly, when any range is called for, intervening numbers that are increments of the difference between the upper limit and the lower limit divided by 10 can be taken as alternative upper or lower limits. For example, if the range is 1.1. to 2.1 the following numbers 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2.0 can be selected as lower or upper limits.

Corrosion may cause degradation in fuel cell bipolar plates. Corrosion is a process by which refined metal is converted to a more chemically stable form such as the metal's oxide(s), hydroxide(s), sulfide(s), and/or other salts. The more chemically stable form may be less desirable because it exhibits one or more less desirable properties or inhibits one or more desirable properties. The conversion may present a steady destruction of the metal material. It may refer to the electrochemical oxidation of the metal with an oxidant such as oxygen. Corrosion may be invoked by exposure of the metal substrate to moisture in the air, to a solution with a relatively low pH, various chemical substances such as acids, microbes, elevated temperatures, and/or other factors. What is needed are alloys for use in fuel cell bipolar plates that have corrosion resistant characteristics. What is also needed are material for bipolar plates that have a relatively high mechanical strength.

is a schematic perspective view of fuel cell. Fuel cellincludes electrode catalyst layerand electrolyte. In one or more embodiments, the fuel cell may include a proton exchange membrane. Fuel cellmay be connected to an external circuit to provide power. Fuel cellmay include bipolar plates. Bipolar plates may provide structural support, conductivity, and may assist in supplying fuel. Bipolar plates may also assist in removal of reaction products or byproducts. Each bipolar plateincludes a flow passageto assist in supplying fuel and/or removing by-products. Bipolar plates may help regulate or manage thermal conditions in a fuel cell. Bipolar plates may contribute significantly to the weight and cost of a fuel cell. Typically, bipolar plates may be made of metal or graphite. In one or more embodiments bipolar platesmay be flow field plates. In one or more embodiments, a fuel cell may include a gas diffusion layer. Bipolar plates may connect and divide individual fuel cells to form a fuel cell stack. Fuel cells may be stacked to increase voltage and/or power.is a side view of fuel cell stack. Fuel cell stackincludes a plurality of fuel cells. Bipolar plates may include a coating, composite, and/or polymer.is a cross-section of a portion of a fuel cell. Bipolar plateincludes a substrate, and a surface layer coating.also includes an electrode catalyst layerand flow passage.is a schematic perspective partial cross-sectional view of a fuel cell stack including a bipolar plate with a substrate′, a surface layer coating′. The bipolar plates define flow passage′, and temperature control channel′. The fuel cell stack includes membrane electrode assembly′.

In one or more embodiments, the depth of flow passagemay be about 0.5 mm. In one or more embodiments, the width of flow passagemay be about 1 mm. In one or more embodiments, flow passagemay be greater than 1 mm.

In one or more embodiments, fuel cellmay be a proton exchange membrane fuel cell (PEMFC). A PEMFC includes a proton exchange membrane. PEMFCs may also be referred to as a polymer electrolyte membrane fuel cells or solid polymer electrolyte fuel cell. A membrane electrode assembly (MEA) refers to the membrane, electrodes and may refer to a catalyst or catalyst layer. The catalyst layer may include carbon paper or a carbon support. In one or more embodiments, the MEA may include a gas diffusion layer. Proton-exchange membrane fuel cells commonly operate in acidic environments and may have increased operating temperatures. For example, a PEMFC may operate between about 20 and 100° C. PEMFCs may be lightweight and generally provide high power densities. Although still elevated, PEMFCs may operate at lower temperatures compared with other fuel cell technologies and may have relatively shorter start up times. Accordingly, lightweight materials and/or anti-corrosive materials may be suitable for use in PEMFCs. The characteristic of PEMFCs make them well suited for mobile transportation technologies.

In one or more embodiments, a proton-exchange membrane may include Nafion XL, Nafion, Nafion, Nafion, and/or Nafion. Nafion membranes may include a fluoropolymer. Electrodes may be made of carbon, carbon cloth and/or carbon fiber. Electrodes may include a catalyst. Catalyst may include but are not limited to platinum, nickel, palladium, and iridium. For example, platinum ruthenium on a carbon support may be used as the electrode catalyst layer.

As described above, corrosion may reduce the life or efficiency of fuel cells. Accordingly, various methods and materials have been employed to inhibit corrosion. Despite these efforts, corrosion remains a persistent impediment to advances in fuel cells.

Due to rising carbon dioxide emissions and the relatively high current dependency on non-renewable fossil fuels as energy carriers in the transportation sector, there is an ever increasing need to develop and commercialize transportation technologies that use clean and sustainable sources of energy. Advances in fuel cell technology may support efforts to a cleaner and more sustainable energy sources. Reduction in cost, weight, improved efficiency and longer life of a fuel cell (including PEMFCs) may be achieved by improvements in bipolar plates.

Bipolar plates may perform various functions including providing structural integrity or support, providing electrical or thermal conductivity, assisting in supplying fuel and/or removing reaction products. Bipolar plates may contribute about 70-80% of the total weight of a proton-exchange membrane fuel cell stack and more than 40% of the cost.

Alloys may provide unique benefits and properties suitable for bipolar plates. As used herein, in one or more embodiments, alloy refers to the mixing or combination of two or more elements. An alloy may include the mixing or combination of one or more metals with one or more metalloids or non-metals. An alloy may be crystalline, partially crystalline or amorphous. Crystalline materials exhibit an ordered structure whereas amorphous materials lack an ordered structure. A common amorphous material is glass. Hence glass, glassy, and amorphous are often used interchangeably. Alloys exhibiting amorphous properties may be referred to as metallic glasses. For example, an alloy may be considered amorphous if it is greater than or equal to 50% amorphous. In still other embodiments, an alloy may be considered amorphous if it is greater than or equal to 75% amorphous. In still more embodiments, an alloy may be considered amorphous if it greater than or equal to 99% amorphous. In one or more embodiments, an alloy may be considered partially amorphous if it is greater than or equal to 5% amorphous but less than 100% amorphous. In other embodiments an alloy may be considered partially amorphous if it is greater than or equal to 10% amorphous but less than 100% amorphous. In still other embodiments, an alloy may be considered partially amorphous if it is greater than or equal to 25% amorphous but less than 100% amorphous. In one or more embodiments, an alloy may be considered partially amorphous if it is greater than or equal to 50% amorphous but less than 100% amorphous. In one or more embodiments, the degree of crystallinity or lack thereof may be determined by using differential scanning calorimetry (DSC). In one or more embodiments, x-ray diffraction (XRD) techniques may be used to determine the presence of ordered structures. In one or more embodiments, differential thermal analysis (DTA) may be used to identify crystallinity. In one or more embodiments, the degree of amorphous structure or crystallinity may be characterized as short-range, medium-range, and long-range order. In one or more embodiments, substantially crystalline structures may exhibit long-range order. In one or more embodiments, amorphous structures may still exhibit short-range order.

In one or more embodiments, amorphous or partially amorphous alloys may exhibit improved mechanical strength and/or corrosion resistance. For example, one or more alloys with an amorphous structure may have a corrosion resistance one to two magnitudes greater than one or more of the alloys with crystalline structures. In one or more embodiments, alloys may have reduced weights. In one or more embodiments, amorphous or partially amorphous alloys may have further reduced weights. For example, one or more alloys including metallic glasses may weigh less than more traditional materials such as steel. In one or more embodiments, amorphous alloys may require controlled cooling or processing. In one or more embodiments, additional cost associated with controlled cooling may be necessary. However, in one or more embodiments, one or more benefits including but not limited to reduced weights, improved efficiency and/or longer lifespan may offset such cost. In one or more embodiments, the alloys described herein may be suitable for making bipolar plates. In one or more embodiments, fully or partially amorphous alloys may be suitable for making bipolar plates or for coating bipolar plates.

Amorphous metal alloys or partially amorphous metal alloys may be referred to as metastable. Metastable materials are stable but not in their most stable form. Metastable materials may need assistance to convert from the metastable state to a more stable state. A more stable state may be a crystalline structure. Metastable materials may need significant assistance, such as increases in temperature before converting from their metastable state to another more stable state. Accelerated cooling may inhibit converting to a more stable state. These materials may be suitable for use in various applications that do not promote leaving the metastable state. However, discovering metastable states can be challenging as such states may not commonly exist. As a result, identifying useful amorphous or partially amorphous alloys has been difficult. Generally, the greater the elemental components and the more diverse the elemental sizes the more likely an amorphous structure will be formed. However, even after identifying fully or partially amorphous alloys such materials may not be useful without tuning and optimization. For example, formability of a material is a practical consideration for any industrial application including the production of bipolar plates. This often requires consideration of various processing parameters such as temperature treatments (e.g. heating and/or cooling processes). Doping and/or additives may also present various opportunities for optimization.

In one or more embodiments, the alloys described herein may have a glass transition temperature (T) and a first onset crystallization temperature (T). In one or more embodiments, the difference between Tand Tmay be used to determine suitable materials. For example, Tmay be greater than or equal to about 10° C. more than T. In one or more embodiments, Tmay be greater than or equal to about 25° C. more than T. In other embodiments, Tmay be greater than or equal to about 49° C. more than T. In one or more embodiments, Tmay be greater than or equal to about 60° C. more than T. In still other embodiments, Tmay be greater than or equal to about 67° C. more than T. In one or more embodiments, Tand Tmay be determined using differential scanning calorimetry (DSC).

One or more machine learning algorithms may be used to determine alloys for bipolar plates. One or more machine learning algorithms may be used to determine fully or partially amorphous alloys for bipolar plates. One or more machine learning algorithms may be trained with experimental data from the Nonequilibrium Phase Diagrams of Ternary Amorphous Alloys from the Landolt-Bornstein collection database. One or more machine learning algorithm may use a series of Random Forest classifiers created with a random subspace method and a set of attributes, to form a type of decision tree. The algorithm may be configured to predict the probability of an alloy forming an amorphous structure. More details regarding this strategy can be located at Ward, Logan, et al., A General-Purpose Machine Learning Framework for Predicting Properties of Inorganic Materials, NPJ COMPUTATIONAL MATERIALS 2 (2016) (available at https://www.nature.com/articles/npjcompumats201628#supplementary-information).

The attributes may include stoichiometric characteristics based on Lnorms where p=0, 2, 3, 5, 7, and 10. For example, the p=2 norm for TiOis

The attributes may include statistics such as the minimum, maximum, range, fraction-weighted mean, average deviation, mode for properties including atomic number, atomic weight, row, column, covalent radius, electronegativity, melting temperature, Mendeleev number, number of d valence electrons, number of f valence electrons, number of s valence electrons, number of p valence electrons, total number of valence electrons, number of unfilled d states, number of unfilled f states, number of unfilled s states, number of unfilled p states, total number of unfilled states, magnetic moment (per atom) of 0 K ground state, space group number of 0 K ground state, specific volume of 0 K ground state, band gap energy of 0 K ground states. The attributes may also include a fraction weighted average of the number of valence electrons in each orbital. The attributes may include a Boolean representing whether a neutral ionic compound may be formed. The attributes may include the mean ionic character and the fraction of ionic character for a binary compound represented by the formula:

where I is the fraction of ionic character, Xis the electronegativity of element A, and Xis the electronegativity of element B.

The machine learning algorithms described herein may be implemented using a computer platformillustrated in. The computing platformmay include a processor, memory, and non-volatile storage. The processormay include one or more devices selected from high-performance computing systems including high-performance cores, microprocessors, micro-controllers, digital signal processors, microcomputers, central processing units, field programmable gate arrays, programmable logic devices, state machines, logic circuits, analog circuits, digital circuits, or any other device that manipulate signals (analog or digital) based on computer-executable instructions residing in the memory. The memorymay include a single memory device or a number of memory devices including, but not limited to, random access memory (RAM), volatile memory, non-volatile memory, static random access memory (SRAM), dynamic random access memory (DRAM), flash memory, cache memory, or any other device capable of storing information. The non-volatile storagemay include one or more persistent data storage devices such as a hard drive, optical drive, tape drive, non-volatile solid state device, cloud storage or any other device capable of persistently storing information.

The processormay be configured to read into memoryand execute computer-executable instructions of the non-volatile storageand embodying one or more of the algorithms described herein. Executable instruction may reside in a software module. The software modulemay include operating systems and applications. The software modulemay be compiled or interpreted from a computer program created using a variety of programming languages and/or technologies, including, without limitation, and either alone or in combination, Java, C, C++, C#, Objective C, Fortran, Pascal, Java Script, Python, Perl, and PL/SQL.

Upon execution by the processor, the computer-executable instruction of the software modulemay cause the computing platformto implement one or more of the algorithms disclosed herein. Non-volatile storagemay also include datasupporting the functions, features, calculations, and processes.

The program code embodying the algorithms described herein is capable of being individually or collectively distributed as a program product in a variety of different form. The program code may be distributed using a computer readable storage medium having computer readable program instructions thereon for causing a processor to carry out aspects. Computer readable storage media, which is inherently non-transitory, may include volatile or non-volatile, and removable and non-removeable tangible media implemented in any method or technology for storage of information, such as computer-readable instructions, data structures, program modules, or other data. Computer readable storage media may further include RAM, ROM, erasable programable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other solid state memory technology, portable compact disc read-only memory (CD-ROM), or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store the desired information and which can be read by a computer. Computer readable program instructions may be downloaded to a computer, another type of programmable data processing apparatus, or another device form of a computer readable storage medium or to an external computer or external storage device via a network.

Computer readable program instructions stored in a computer readable medium may be used to direct a computer, other types of programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions that implement functions, acts, and/or operations described herein. The functions, acts, and/or operations described herein may be re-ordered, processed serially, and/or processed concurrently.

One or more additional considerations may be used to determine alloys suitable for bipolar plates. For example, alloys including a significant amount of one or more of the following elements beryllium (Be), arsenic (As), cadmium (Cd), mercury (Hg), thallium (Tl), and lead (Pb) may not be suitable for bipolar plates because these elements may be considered toxic. As another example, alloys including a significant amount of one or more of the following elements lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), and ytterbium (Yb) may not be suitable for bipolar plates because of significant expense associated with mining ore-deposits for these elements. In yet another example, alloys including a significant amount of one or more of the precious metals rhenium (Re), ruthenium (Ru), rhodium (Rh), palladium (Pd), silver (Ag), osmium (Os), iridium (Ir), platinum (Pt), and gold (Au) may not be suitable for bipolar plates because of the significant expense of these elements. Also, in one or more embodiments, alloys including a significant amount of one or more of the elements gallium (Ga), germanium (Ge), yttrium (Y), indium (In), and hafnium (Hf) may not be suitable for bipolar plates because the scarcity of these elements. Based on the above analysis, in one or more embodiments, aluminum (Al), carbon (C), copper (Cu), iron (Fe), manganese (Mn), nickel (Ni), silicon (Si), and titanium (Ti) have been identified as viable options for bipolar plates.

Alloys including partially or fully amorphous alloys may be suitable for bipolar plates. In one or more embodiments, one or more alloys may be used to form a bipolar plate. In one or more embodiments, a bipolar plate may be coated with one or more alloys. In one or more embodiments, one or more alloys may be applied to a bipolar plate.

In one or more embodiments, a bipolar plate may include an alloy of aluminum (Al), copper (Cu), and titanium (Ti). The composition of an alloy may be represented by the following formula:AlCuTi  (3)where x is more than or equal to 0 and less than or equal to 0.885 (0≤x≤0.885); y is more than or equal to 0 and less than or equal to 0.85 (0≤y≤0.85); z is more than or equal to 0.05 and less than or equal to 0.8 (0.05≤z≤0.8), and x+y+z=1.

In other embodiments, x is more than or equal to 0 and less than or equal to 0.55 (0≤x≤0.55); y is more than or equal to 0.25 and less than or equal to 0.75 (0.25≤y≤0.75); and z is more than or equal to 0.05 and less than or equal to 0.65 (0.05≤z≤0.65). For example, x may be any of the following numbers or in a range of any two of the numbers 0, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5, and 0.55; y may be any of the following numbers or in a range of any two of the numbers 0.25, 0.3, 0.35, 0.4, 0.45, 0.5, 0.55, 0.60, 0.65, 0.7, and 0.75; and z may be any of the following numbers or in a range of any two of the numbers 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5, 0.55, 0.6, and 0.65.

For example, the composition represented by the formula AlCuTimay be used. Additional embodiments may use one or more of the following compositions AlCuTi, AlCuTi, AlCuTi, AlCuTi, AlCuTi, AlCuTi, AlCuTi, AlCuTi, AlCuTi, and AlCuTi. Additional embodiment may include one or more of the compositions represented in.

One or more compositions may have a higher aluminum (Al) content and produce a lower weight material. For example, some embodiments using the composition AlCuTiwith a higher amount of aluminum have a lower weight as compared to an iron-based or steel material. Other embodiments with compositions having a high aluminum content may also be lightweight materials suitable for bipolar plates. For example, x may be greater than or equal to 0.1 and may exhibit weights less than traditional steel alloys. In one or more embodiments x may be greater than or equal to 0.25 and may exhibit even lower weights compared with traditional steel materials. In one or more embodiments x may be greater than or equal 0.45 and may exhibit considerably lower weights compared with traditional materials. For example, x may be any of the following numbers or in a range of any two of the numbers 0.55, 0.54, 0.53, 0.52, 0.53, 0.52, 0.51, 0.50, 0.49, 0.48, 0.47, 0.46, and 0.45.

One or more compositions may have more copper and greater thermal and/or electrical conductivity. For example, y may be greater than or equal to 0.5 and may have greater conductivity. In one or more embodiments y may be greater than 0.65 and may have further improved conductivity. For example, y may be any of the following numbers or in a range of any two of the numbers 0.65, 0.66, 0.67, 0.68, 0.69, 0.7, 0.71, 0.72, 0.73, 0.74, and 0.75.

One or more compositions may have less titanium and reduced cost. For example, z may be less than or equal to 0.4 and may have reduced cost. In one or more embodiments, z may be less than or equal to 0.25 and may have further reduced cost. In one or more embodiments, z may be less than or equal to 0.1 and may have exceptionally lower cost. For example, z may be any of the following numbers or in a range of any two of the numbers 0.05, 0.06, 0.07, 0.08, 0.09, and 0.1.

One or more compositions may have more titanium and may exhibit higher corrosion-resistant properties. For example, z may be more than or equal 0.1 and may exhibit greater corrosion resistance. In one or more embodiments z may be more than or equal to 0.25 and may exhibit even greater corrosion resistance. In one or more embodiments, z may be more than or equal to 0.45 and exceptional corrosion resistance may be obtained. For example, z may be any of the following numbers or in a range of any two of the numbers 0.55, 0.56, 0.57, 0.58, 0.59, 0.6, 0.61, 0.62, 0.63, 0.64, and 0.65.

In one or more embodiments, an alloy including aluminum (Al), copper (Cu), and titanium (Ti) may be produced by mixing aluminum, copper and titanium powders in the appropriate proportions as discussed herein. In one or more embodiments, the powder mixture may then be introduced to a high-energy mechanical alloying process. In one or more embodiments, mechanical alloying may occur under an inert environment.

For example, an alloy may be formed by mixing elemental powders of aluminum (Al), copper (Cu), and titanium (Ti) in proportions discussed herein. The elemental powders may be greater than or equal to 99.5% purity with a particle size of 45 to 100 μm. In one or more embodiments, a Retsch PM 400 high-energy planetary ball mill may be used for mechanically alloying under an argon (Ar) atmosphere. Stainless steel balls with a diameter of 10 mm may be used as a milling medium. In one or more embodiments, the weight of milling medium used may be 10 times as much as the weight of the powder. In one or more embodiments, the rotational speed of the high-energy planetary ball mill may be 300 rotations per minute (rpm). In one or more embodiments, stearic acid may be used as a processing agent. In one or more embodiments, stearic acid may prevent the elemental powders from adhering to the milling medium or ball mill. For example, stearic acid may be added at less than or equal to 1% by weight of the elemental powders. In one or more embodiments, the powders may be milled for greater than or equal to 30 hours to form a glassy powder. In one or more embodiments, a partially or fully amorphous alloy may be formed. In one or more embodiments, a glassy powder may be processed at 250° C.±5° C. to form a bipolar plate or to coat a substrate to form a bipolar plate. In one or more embodiments, a glassy powder may be processed at greater than 250° C. In one or more embodiments, a rapid cooling technique may be used.

In one or more embodiments, the elemental powder particles may be irregularly shaped. In one or more embodiments, the aluminum (Al) powder may have a wide particle size distribution. In one or more embodiments, the aluminum (Al) powder may have a narrow particle size distribution. In one or more embodiments, the aluminum (Al) powder may have a mean particle diameter of about 53 μm. In one or more embodiments, the glassy powder may have an irregular particle shape. In one or more embodiments, the glassy powder may have mean particle diameter of about 7 μm. In one or more embodiments, the glassy powder may have a narrow particle size distribution.